Factory Layout Design Based on Systematic Layout Planning for Electronic Fabrication

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By

Christian Michael Reza 11210097

A thesis submitted to the Faculty of

ENGINEERING AND INFORMATION TECHNOLOGY in partial fulfillment of the requirements

for the

BACHELOR’S DEGREE in

INDUSTRIAL ENGINEERING

SWISS GERMAN UNIVERSITY EduTown BSD City

Tangerang 15339 Indonesia

Revision After Thesis Defense on 22 July 2014

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Christian Michael Reza STATEMENT BY THE AUTHOR

I hereby declare that this submission is my own work and to the best of my knowledge, it contains no material previously published or written by another person, nor material which to a substantial extent has been accepted for the award of any other degree or diploma at any educational institution, except where due acknowledgement is made in the thesis.

Christian Michael Reza

_____________________________________________

Student Date

Approved by:

Dr. Ir. Prianggada Indra Tanaya, MME.

_____________________________________________

Thesis Advisor Date

Dr. Ir. Tutuko Prajogo, MSMfgE.

_____________________________________________

Thesis Co-Advisor Date

Dipl. –Ing. Maralo Sinaga

_____________________________________________

Thesis Co-Advisor Date

Dr. Ir. Gembong Baskoro, M.Sc.

_____________________________________________

Dean Date

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Christian Michael Reza ABSTRACT

VIRTUAL FACTORY: FACTORY LAYOUT DESIGN BASED ON SYSTEMATIC LAYOUT PLANNING (SLP) FOR ELECTRONIC FABRICATION

EXAMPLE: MOTHERBOARD FABRICATION By

Dr. Ir. Prianggada Indra Tanaya, MME., Advisor Dr. Ir. Tutuko Prajogo, MSMfgE., Co-Advisor

Dipl. –Ing. Maralo Sinaga, Co-Advisor SWISS GERMAN UNIVERSITY

Systematic Layout Planning method for factory layout has been learned several times for thesis program. Application of this method is basically concentered to manufacturing factory for metal fabrication. Electronics fabrication is made as an option to learn the differentiation of pattern on designing factory layout. Discrete products between metal and electronics fabrication is approximately the same.

Especially for electronic fabrication, almost all the procedures are executed in gradually way and the velocity of parts placement and handling is quick. Procedures of electronic fabrication has to be defined and basically to be described as a display.

The output will provide a change to the application of production time and cost.

Optimal design of the factory layout will be implemented and the best solution needs to be delivered. Discrete Event Simulation application needs to be used to confirm the time validity and possible bottleneck that may happen.

Keywords: systematic layout planning, factory layout, electronic fabrication, discrete event simulation.

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Christian Michael Reza DEDICATION

I dedicate this works to my lovely family and friends, for their support, constant helping hands, and companions.

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Christian Michael Reza ACKNOWLEDGEMENTS

First and foremost, I would like to express endless gratitude to God, for his blessings and guidance throughout the creation and completion of this thesis.

I especially want to thank to my advisor Dr. Ir. Prianggada Indra Tanaya, MME. and my co-advisor Dr. Ir. Tutuko Prajogo, MSMfgE. and Dipl.-Ing. Maralo Sinaga, for the guidance during my thesis work at Swiss German University. Their willingness to constantly help, guide, and motivate contribute tremendously to the completion of this thesis.

I also would like to thank to Aditya Tirta Pratama, S.Si, MT. and Cepi Muhammad Hanafi, SST., MT, lectures of Engineering for their help and giving me informations according to my topic in this thesis.

To all my friends in Industrial Engineering ’10, Mechatronics ’10, and Life Science

’10 for the friendship, support, and help in the past for years.

Last but not least, my deepest gratitude goes to my family for their love and support throughout the process of writing this thesis.

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Christian Michael Reza TABLE OF CONTENTS

STATEMENT BY THE AUTHOR ... 2

ABSTRACT ... 3

DEDICATION ... 5

ACKNOWLEDGEMENTS ... 6

TABLE OF CONTENTS ... 7

LIST OF FIGURES ... 11

LIST OF TABLES ... 13

LIST OF APPENDIX ... 14

1. CHAPTER 1 - INTRODUCTION ... 17

1.1. Background ... 17

1.2. Problem Identification ... 18

1.3. Thesis Purpose ... 18

1.4. Thesis Scope ... 18

1.5. Thesis Limitation ... 19

1.6. Thesis Organization ... 20

2. CHAPTER 2 - LITERATURE REVIEW ... 21

2.1. Introduction... 21

2.2. Factory Layout ... 21

2.2.1. Analysis Plant Layout Design for Effective Production [1] ... 21

2.3. Systematic Layout Planning (SLP) ... 22

2.3.1. Systematic Layout Planning (SLP) Implementation in PT. Sanken Argadwija [2]... 22

2.3.2. Redesigning Layout at PT. Inkoasku to Increase Productivity by Using Systematic Layout Planning (SLP) Method and Discrete Event Simulation Model [3] ... 23

2.3.3. Cellular Manufacturing Layout Design and Selection: A Case Study of Electronic Manufacturing Service Plant [4] ... 23

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Christian Michael Reza 2.3.4. Improvement in Layout Design using SLP of a small size manufacturing

unit: A case study [5] ... 24

2.4. Assembly Line Balancing ... 24

2.4.1. Productivity Improvement through Line Balancing [6] ... 25

2.4.2. Assembly Line Balancing using Simulation Technique in a Garment Manufacturing Firm [7] ... 25

2.5. Discrete Event Simulation (DES) ... 26

2.5.1. Optimization of Layout Using Discrete Event Simulation [8] ... 26

2.5.2. Analysis, Synthesis & Discrete Event Simulation to Increase Productivity of Pump Packaging System [9] ... 27

2.6. Lean Manufacturing ... 27

2.6.1. Design and Implementation of Lean Facility Layout System of a Production Line [10] ... 27

2.6.2. Study and Implementation of Lean Manufacturing in a Garment Manufacturing Company: Bangladesh Perspective [11] ... 28

2.7. Electronics Fabrication ... 29

2.7.1. Techniques and Applications of Production Planning in Electronics Manufacturing Systems [12] ... 29

2.7.2. Developing and Deploying Electronics Assembly Line Optimization Tools: A Motorola Case Study [13] ... 29

2.8. Active Vibration Control ... 30

2.8.1. An Overview of Recent Automotive Applications of Active Vibration Control [14] ... 30

2.8.2. Vibration Analysis of PCBs and Electronic Components [15] ... 31

3. CHAPTER 3 – METHODOLOGY ... 32

3.2. Problem Identification ... 32

3.3. Background Theory ... 32

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3.3.1. Factory Layout ... 32

3.3.2. Systematic Layout Planning ... 36

3.3.3. Assembly Line Balancing ... 43

3.3.4. Electronics Fabrication ... 44

3.3.5. Lean Manufacturing ... 45

3.3.6. Active Vibration Control ... 46

3.3.7. Discrete Event Simulation ... 47

3.3.8. ABC Analysis ... 47

3.3.9. Simulation ... 48

3.4. Project Methodology ... 53

3.4.1. Preliminary Study ... 55

3.4.2. Data Collection... 55

3.4.3. Data Analysis ... 55

3.5. Software Tools ... 58

4. CHAPTER 4 – RESULTS AND DISCUSSIONS ... 59

4.2. Input Data Analysis ... 59

4.2.1. Product Analysis ... 59

4.2.2. Demand Forecast (Quantity Analysis) ... 67

4.2.3. ABC Analysis ... 68

4.2.4. Operation Process Chart (Routing Analysis) ... 68

4.2.5. List of Area (Support Services Analysis) ... 86

4.2.6. Working Time (Time Analysis) ... 89

4.3. Flow and Activity Analysis ... 90

4.3.1. Activity Relationship Chart ... 90

4.3.2. Activity Relationship Worksheet ... 92

4.3.3. Dimensionless Block Diagram... 103

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4.3.4. Activity Relationship Diagram ... 106

4.4. Design Development ... 117

4.4.1. Operation Process Cycle Time ... 117

4.4.2. Lead Time Calculation ... 120

4.4.3. Assembly Line Balancing ... 121

4.4.4. Average Cycle Time Calculation ... 121

4.4.5. Worker Calculation ... 125

4.4.6. Space Requirement (Area Planning) ... 127

4.4.7. Drafting the Layout ... 136

4.5. Simulation ... 141

4.5.1. Introduction ... 141

4.5.2. Conceptual Model ... 141

4.5.3. Assumption ... 143

4.5.4. Parameter Measured ... 143

4.5.5. Model Translation ... 143

4.5.6. Model Verification ... 149

4.5.7. Model Validation... 149

4.5.8. Simulation Result and Result Analysis ... 150

4.6. Concluding Remark ... 154

5. CHAPTER 5 – CONCLUSIONS AND RECCOMENDATION ... 156

5.1. Conclusion ... 156

5.2. Further Development... 157

GLOSSARY ... 158

REFERENCES ... 159

APPENDIX ... 161

CURRICULUM VITAE ... 228